A Computer-Aided System for Sustainability Analysis for the Die-Casting Process

2012 ◽  
Author(s):  
Princepal Singh ◽  
Jatinder Madan ◽  
Amrik Singh ◽  
Mahesh Mani
Keyword(s):  
Carbon Emissions ◽  
Material Properties ◽  
Energy Use ◽  
Die Casting ◽  
Casting Process ◽  
Shop Floor ◽  
Sustainability Analysis ◽  
Computer Aided ◽  
Die Casting Process ◽  
Casting Industry

Currently available sustainability analysis systems for the die-casting process primarily depend on the material properties and do not account for process information. As a result they are unable to assess or compare the sustainability of parts made using different process plans. In this paper, we propose a new computer-aided system named Sustainability Analyzer for Die-casting Process. Here, we discuss the details of the architecture and the working of the proposed system. We analyze sustainability using three sustainability indicators, namely energy use, solid waste and carbon emissions. The proposed system is verified by comparing results with the actual data measured from the shop floor. The proposed system is beneficial for sustainability analysis comparing different plans alongside material properties, ultimately helping the die-casting industry to reduce carbon emissions and material waste besides improving energy efficiency.

Microstructure and Mechanical Properties of Al Alloys by Semi-Solid Processing with LSPSF Technology

2009 ◽  
Vol 628-629 ◽  
pp. 477-482 ◽  
Author(s):  
Hong Min Guo ◽  
Xiang Jie Yang ◽  
J.X. Wang
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloys ◽  
Die Casting ◽  
High Strength ◽  
Casting Process ◽  
Homogeneous Distribution ◽  
Casting Alloy ◽  
Die Casting Process ◽  
Casting Industry ◽  
Semi Solid

Rheoforming is becoming the choice of the casting industry which relies on the semi-solid slurry for high integrity structural parts. The potential of rheoforming with LSPSF (Low superheat pouring with a shear field) for aluminum alloys was investigated in the present work. High quality semi-solid slurries of a series of aluminum alloys were manufactured by LSPSF process, such as casting alloy A356, high strength alloy 201, secondary die casting alloy A380 and wrought alloy 2024, 6082 and 7075, in which the primary α-Al presented spherical, small and homogeneous distribution, especially with zero-entrapped liquid. Applications of LSPSF in high pressure die casting process and squeeze casting process were presented. Results showed that LSPSF rheoforming could improve microstructures and increase mechanical properties.

scholarly journals Casting Techniques: An Alternative for Producing Parts with Recycled Al in the Gravity Die Casting Process

2021 ◽  
Author(s):  
Narducci Carlos Jr.
Keyword(s):  
Material Properties ◽  
Die Casting ◽  
Test Procedure ◽  
Casting Process ◽  
Optical Microscope ◽  
Mechanical Tests ◽  
Metal Mold ◽  
Heat Treated ◽  
Die Casting Process ◽  
Size And Morphology

This work applied the grain refinement technique by heterogeneous nucleation and precipitation hardening to investigate the effect of size and morphology of β-Fe particles on Al-Si alloys\' mechanical behavior Fe-critical, inoculated via Nb+B and heat-treated. The samples for the microstructural analyses were produced according to the standard mold, Test Procedure-1 (TP-1) and, analyzed by optical microscope with polarised light and filter plate and differential interference contrast (DIC) and by X-ray energy dispersive spectroscopy (XRD SEM) with EDS detector analyzer. The specimens for the mechanical tests were cast in a metal mold according to ASTM B108. The combined effect of manipulating the studied alloy Al10Si1Fe0.35Mg resulted in reduced and spheroidized β-Fe precipitates with improved mechanical properties in the material. Properties are similar to those achieved by commercially used alloys with engineering applications in structural and safety parts.

scholarly journals A REVIEW OF MAIN SUSTAINABILITY CHALLENGES IN ALUMINIUM DIE CASTING INDUSTRY

2017 ◽  
pp. 023
Author(s):  
Emilija Kozhovska
Keyword(s):  
Die Casting ◽  
Cooling Water ◽  
Casting Process ◽  
Energy Resources ◽  
Economic Sustainability ◽  
Low Costs ◽  
Die Casting Process ◽  
To Come ◽  
Casting Industry ◽  
Sustainability Challenges

Aluminium die casted parts are in demand by many industries, and their relatively low costs, lightweight, as well as accurate dimensions and shapes give reason to predict that aluminium will be dominant metal in industry for years to come. Aluminium die casting process includes a variety of materials and energy resources. Die casting process uses significant quantities of energy, as well as auxiliary materials like oil-based lubricants and cooling water. This article presents an outline of the environmental, social, and economic sustainability issues related to aluminium die casting process.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

Development of 2-Cavity Die Casting Process for AM50 Mg Steering Column Lock Housing Module

2006 ◽  
Vol 510-511 ◽  
pp. 334-337
Author(s):  
Shae K. Kim
Keyword(s):  
Magnesium Alloy ◽  
Aluminum Alloys ◽  
Magnesium Alloys ◽  
Weight Reduction ◽  
Die Casting ◽  
Casting Process ◽  
Research Strategy ◽  
Good Choice ◽  
Weight Basis ◽  
Die Casting Process

It is obvious that automotive industry worldwide is predicting significant growth in the use of magnesium alloys for weight reduction to decrease fuel consumption and emission. About a half decade ago, the price of magnesium alloys was more than twice that of aluminum alloys on a weight basis. Currently, magnesium alloys cost about one and a half times that of aluminum alloys on a weight basis, and thus the price of magnesium alloys is the same as or lower than that of aluminum alloys on a per volume basis. However, in considering the performance of magnesium components (not their specific mechanical properties) and recycling aspect of magnesium alloys, it is required to realize niche applications of magnesium alloys, which meet the cost requirement on performance basis and/or offer more than weight reduction. There are many other factors that make magnesium a good choice: component consolidation, improved safety for driver and passengers, and improved noise vibration and harshness (NVH), to name a few. As one of these efforts to adopt magnesium alloys in automotive component, this paper describes the research strategy of cold chamber type 2-cavity die casting of AM50 magnesium alloy for developing the steering column lock housing module with emphasis on cost driving factors and necessities for cost reduction, explaining why AM50 magnesium alloy is chosen with design and die casting process optimization.

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